Method for making textured panels

ABSTRACT

This invention pertains to the method, and/or apparatus for rapidly producing the same so that fibrous board products including plywood panels would appear to simulate an adze surfaced product having a rustic appearance. The &#39;&#39;&#39;&#39;distressing&#39;&#39;&#39;&#39; or cutting of the product may be minimal or partial distressing or may be total distressing including overlapping cuts, or cuts within previous cuts.

D 1 ilmie States Patent 11 1 1111 3,726,328 Luebs et a1. 5] Apr. M, 1973 MEOD FOR MAKING TEXTURED [56] References Cited PANELS UNITED STATES PATENTS [75] Inventors: Donald F. Luebs, Vienna, Va.;

Frederick Ashby, Red Oak 585,886 7/1897 Lerch ..144/ 13 Ridge, N.Y. 857,738 6/1907 Karstens ..144/l36 R 945,373 1/1910 Brook ..144/2 R Assigneei Champion International p 1,629,742 5 1927 SCOtI ..144/136 R tion, New York, N.Y. [22] Filed; 25 97 Primary ExaminerDonald R. Schran Att0rneyJames M. Heilman and Heilman & Heilman [21] Appl. No.: 118,666

Related US. Application Data [57] ABSTRACT [62] Division of s61. Nos. 759,624, Sept. 13, 1968, and This inventiOn pertains the method and/c S61. No. Division of Ser. No. 35,01 1, May 6, 1970, Paralus for p y Producmg the Same SO that fibrous Pat. No. 3,616,826, and Ser. No. Division of Set. board products including plywood panels would ap- No. 118,665. pear to simulate an adze surfaced product having a rustic appearance. The distressing or cutting of the UuS- A; product may be or distressing or may [51] Int. Cl. ..B27m 3/08 be total distressing including Overlapping cuts, or cuts 58 Field of Search ..144/320, 323, 326, within previous cuts.

4 Claims, 6 Drawing Figures PATENTEDAFR 1 01375 SHEET 1 UF 2 5 mm R T m wm WA D Drr ATTORNEY.

PATENTEDAPRI 01w 3, 726,328

SHEET 2 BF 2 INVENTORS DONALD F. LUEBS FREDERICK R. ASHBY ATTORNEY.

METHOD .FOR MAKING TEXTURED PANELS RELATED APPLICATIONS This application is a division of parent application S.N. 759,624, filed Sept. 13, 1968, and copending application S.N. 35,011, filed May 6,1970, now US. Pat. No.3,6l6,826, granted Nov. 2, 1971, and application S.N. 118,665, filed herewith, all of which are incorporated herein by reference, and all assigned to the same assignee hereof.

This invention pertains to a textured panel simulating preferably a rough hewn product, and the method, and apparatus for rapidly producing the same so that the wood fiber boards including plywood panels would appear to simulate an adze surfaced product having a rustic appearance. The distressing or cutting of the product may be minimal or partial distressing or may be total distressing including overlapping cuts, or cuts in cuts.

The hand hewn effect is simulated by feeding plywood panels (which is understood to include all types of fibrous boards) longitudinally under transversely spaced rotary I cutters having respective lifting mechanisms controlled by a programming device.

BACKGROUND board, particle board and the like, and has one of its most effective uses in exterior plywood siding panels.

The number'of cuts made in a-panel or board may rangefrom two to thre'e' cuts per square foot of surface area to cuts which cover the entire surface, and including double cuts in certain areas.

, SUMMARY FIG. 4 is a partial plan view of a portion of a totally distressed panel; and p I FIG. 5 is an enlarged longitudinal section taken on line 5 5 of FIG. 3 showing a five ply panel having the According to the present invention, an interior or ex- DRAWINGS FIG. 1 is a plan view of a preferred-embodiment of apparatus according I to, and for carrying out the method of, the present invention;

' FIG. 2 is a vertical longitudinal section taken along the line 2 2 ofFIG. 1;

FIG. 3 is a plan view of a plywood panel partially distressed by the invention;

FIG. 3A is a cross sectional view taken on the line 3A 3A ofFIG. 3;

face veneer distressed by the invention.

DESCRIPTION OF ONE PREFERRED EMBODIMENT As shown in FIGS. 1 and 2, the machine comprises a bed 10 which supports a plywood panel workpiece 12 of three, five or more plies, and having on each side a conveyor chain 14 driven through a common shaft by a conventional motor (not shown). The chain 14 is provided with dogs 16 for engaging the rear edge of the panel for feeding the panel along the bed 10 to pass under a transversely spaced series of cutting means,

such as cutter heads 18. A fence 20 on each side of the bed III is adjustable for alignment of different widths of work. v

The cutter heads l8, which may be of the same or different widths, are journaled on the ends of arms 22' pivoted on a drive shaft 24 driven by a motor 26. The cutter heads 18 are driven from the shaft 24 by belts not shown for sake of clarity. The arms 22 are conappearance in the panel, simulating the adze marks in a i hand hewn beam. The nature of the individual cuts in this process can be varied through several means. The length of the cut depends upon the time interval in which the cutter head is held in engagement against the panel, as well as the speed of the panel feed.'The width is determined by the width of the knives in th'e'cutter used,'or the shape of the knives may be varied or they may be patterned to provide a textured cut. The transverse spacing of the cutter heads obviously may be varied. Certain of said cuts will be formed in the original-surface of the panel sometimes leaving large areas uncut. Other cuts will be formed within and overlappingprevious cut-out sections, i.e., cuts in cuts.

As mentioned above, the individual single cut-out portions may vary greatly depending upon individual preference. It has been found that one-half to three inches in length, preferably about three inches, one- I FIG. 3A by grooves 39, or by V grooves 39' as illustrated in FIG. 4.

For the information of the Examiner, a representative advertisement of the new products (Oldbridge, trademark of assignee U.S. Plywood-Champion Papers Inc.) made by this invention is attached hereto as Exhibit F which illustrate more dramatically than the drawing the startling effects achieved by the invention either in the rough or with various appropriate stains and/or finishes applied thereto.

Also the tearout which occurs along the rear edge of the cut will vary somewhat depending on the characteristics of the wood. Furthermore, the multiple, rotating cutter heads as described up to this point may be substituted by ganged saw blades (similar to dado heads), rotating abrasive heads, or by fixed knives (scrapers) to be brought into engagement against the panel according to a predetermined pattern similar to that used with the cutter heads. Furthermore, a number of knives may be affixed in an elongated cutter head (similar to a planing machine) which would rotate to scoop or gouge out a pattern of cuts according to placement of the knives. Also, the simulated adze marks may be produced by the removal of material through sand blast or shot blast, with or without a stencil or mask, or by hot or cold embossing of the surface by hot or cold dies, rolls, or platens.

Preferably, a second, third or fourth series of distressing tools (not shown for sake ofclarity), with different height of cutting edge to produce varying depth of cuts can be positioned along the face of the panel to make as many marks in the panel of whatever pattern desired. While most of the cuts will gouge out the wood, other cuts may be employed, alone or in combination with the gouges, which merely mark, compress, or slit the wood, said marks, compressed areas, and slitted areas being of various depth, length, and width suitable to produce the desired effect. Also to further randomize the pattern, if desired, the banks of cutter heads may be oscillated in a slight side to side motion.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

l. A method of treating the surface of a wood panel to simulate a textured hand hewn effect, which comprises:

a. passing the panel lengthwise with respect to transversely spaced rigid cutting tools stationed along the path of said panel;

b. rotating said tools about an axis transverse to the length of the panel;

0. advancing said tools intermittently by hydraulic means toward the moving panel to gouge out spaced areas of the adjacent surface thereof in a predetermined pattern;

d. and controlling the hydraulic means to position the tools by a series of valves and a rotatable program cylinder with control means coupled to the valves.

2. A method as claimed in claim 1 wherein said tools are continuously rotated about their own axes.

3. A method as claimed in claim 1 wherein said rotatable program means is coupled to the means which moves the panel lengthwise.

4. A method as claimed in claim 1 wherein said tools are independently movable with respect to each other.

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2. A method as claimed in claim 1 wherein said tools are continuously rotated about their own axes.
 3. A method as claimed in claim 1 wherein said rotatable program means is coupled to the means which moves the panel lengthwise.
 4. A method as claimed in claim 1 wherein said tools are independently movable with respect to each other. 